Saad Mazhar

• Maintenance: Lead and supervise ‘Corrective, Preventive and Predictive Maintenance’ of Plant Machinery and Plant Utilities and implementing process improvement tool to improve equipment efficiency.
• Spares: Ensure that a proper mechanism is in place for the availability of critical spares as and when required for maintenance purposes with optimal inventory level of spares maintained at all times. Assist Supply Chain department in selecting quality suppliers for new parts as well as in negotiation of prices with suppliers and reaching an acceptable cost for the parts.
• SAP Plant Maintenance Module: Ensure all activities related to breakdown, preventive maintenance, spares etc. and data related to newly added machines is recorded and updated on time in SAP.
• Projects and In-House Machine Design: Lead and supervise team on new projects and also to design and develop automated Machines with updated control systems (PLC controlled) to work under controlled and safe environment.
• Budget and Training: Preparation of departmental budget and monitoring actual expenses incurred against current years’ budget. Ensure all training needs of maintenance staff are evaluated, completed, and renewed as needed with proper on job training to JTMs for developing their skill sets and developing multi skill level JTMs.

• Managing complete maintenance of the following business systems of the automotive industry
 Thermal System Business (Heat Exchanger, Air Con, Starter and Alternator Plants)
 Electrical Systems Business (Wire Harness Plant)
• Leading Electrical, Mechanical and Instrumentation teams to ensure smooth operation, periodic inspection and condition-based monitoring of plant machinery and utility equipment.
• Coordinating new commissioning projects along with modification of old equipment incorporating technological advancements.
• Conducting inter-departmental meetings for the analysis of Downtime reports and focusing on the utilization of time effectively in production by reducing Downtime.
• Costing, budgeting, and purchasing of machinery and equipment by making a comparative analysis of quotations and negotiation with suppliers/vendors.
• Formulating Annual Budget for plant machinery and utility operations.
• Arranging regular development sessions for honing skills of Plant Engineering Team.
• Effective Inventory Management leading to Cost Saving.
• Integration of SAP Maintenance Module for handling correctional and preventive maintenance activities.
• Initiating Industrial Energy saving projects.

• Providing full support to production departments for maintenance activities.
• Attending inter-departmental meetings for enhancing plant efficiency.
• Responsible for reviewing vendor drawing and checking of single lines, schematics and wiring diagrams, grounding, panel/cable schedules, equipment layout, cable layout, tray layout, lighting, and installation.
• Implementation of Process Improvement tools such as Root Cause Analysis, Fish Bone Analysis, PDCA and other QCC tools to reduce downtime.
• Innovation in Machines through proper Electrical/Electronic system to enhance quality and production.

Improved machine accessibility and decreased machine breakdown time by usage of remedial and preventive upkeep frameworks on PLC based Die Casting, Iron and Aluminum Melting and Holding Furnaces, CNC, Wire cut and EDM Machines which improved their effectiveness and dependability. Completed improvement projects and incorporated PLCs and HMIs to maximize equipment efficiency.

Enhanced machine availability and reduced machine breakdown time by the implementation of corrective and preventive maintenance systems on CNC based Machines, Press and Bending machines which resulted in increasing their efficiency and reliability.

Designed Testing Units used for Checking Speedometers and Microcontroller Based Projects.